Tracker Off-Road 800SX User manual

800SX
SERVICE MANUAL
p/n: 2263-005
9/20

1
Table of Contents
General Information/Foreword ....................................... 2
Specifications ............................................................... 2
Torque Specifications ................................................... 3
Torque Conversions (ft-lb/N-m)..................................... 4
Gasoline — Oil — Lubricant ......................................... 4
Preparation for Storage ................................................ 5
Preparation after Storage ............................................. 6
Periodic Maintenance/Tune-Up ...................................... 7
CVT Air Inlet.................................................................. 7
Engine Air Filter ............................................................ 7
Valve Clearance.......................................................... 10
Spark Plug ...................................................................11
Muffler/Spark Arrester..................................................11
Engine Oil — Filter ......................................................11
Front Differential Lubricant — Transaxle Fluid ........... 12
Driveshaft/Coupling .................................................... 13
Headlight — Taillight/Brake Light................................ 13
Shift Cable .................................................................. 16
Hydraulic Brake System ............................................. 17
Burnishing Brake Pads ............................................... 19
Checking/Replacing Drive Belt ................................... 19
Steering/Body/Controls ................................................ 22
Steering Wheel ........................................................... 22
Steering System ......................................................... 22
Steering Knuckles....................................................... 29
Accelerator Pedal ....................................................... 31
Throttle Cable ............................................................. 31
Shift Lever .................................................................. 31
Shift Cable .................................................................. 33
LCD Gauge................................................................. 35
Front Wheel Alignment ............................................... 35
Hood ........................................................................... 36
Front Fenders/Fender Flares...................................... 40
Doors .......................................................................... 44
Roof (Optional) ........................................................... 44
Front Bumper (Optional)............................................. 44
Rear Bumper (Optional).............................................. 45
Dashboard (Mid/Upper) .............................................. 48
Dashboard (Lower)..................................................... 49
Splash Panel .............................................................. 51
Skid Plates.................................................................. 52
Muffler......................................................................... 52
Cargo Box................................................................... 52
Seats .......................................................................... 54
Behind-the-Seat Storage Box Panel........................... 56
Seat Base ................................................................... 58
Troubleshooting .......................................................... 59
Engine ............................................................................ 60
Removing Engine........................................................60
Cylinder Head and Related Components....................65
Removing Cylinder Head and Related Components...65
Servicing Left-Side Components.................................84
Engine Block and Components ...................................93
Installing Engine..........................................................95
Troubleshooting...........................................................99
Fuel/Lubrication/Cooling............................................ 101
Throttle Body.............................................................101
Gas Tank ...................................................................101
Oil Filter/Oil Pump .....................................................102
Liquid Cooling System ..............................................103
Troubleshooting.........................................................108
Electrical System ........................................................ 109
Battery.......................................................................109
Electronic Power Steering (EPS) ..............................109
Ignition Switch ........................................................... 111
Ignition Coils.............................................................. 111
Accessory Receptacle/Connector ............................. 112
Switches.................................................................... 112
Fan Motor.................................................................. 115
Lights......................................................................... 115
Power Distribution Module (PDM)............................. 116
EFI Sensors/Components ......................................... 117
Winch ........................................................................123
Starter Motor .............................................................124
Starter Relay .............................................................125
Alternator/Regulator ..................................................126
Electronic Control Module (ECM)..............................127
Gauge Diagnostic Menu............................................127
Diagnostic Trouble Codes (DTC) ..............................130
Wiring Diagram..........................................................134
Troubleshooting.........................................................135
Drive System ............................................................... 136
Front Drive Actuator ..................................................136
Front Differential........................................................137
Drive Axles ................................................................148
Driveshaft ..................................................................151
Transaxle...................................................................152
Hub/Brake Disc .........................................................170
Hydraulic Brake Caliper.............................................172
Troubleshooting Drive System ..................................176
Troubleshooting Brake System .................................176
Suspension.................................................................. 177
Shock Absorbers .......................................................177
Front A-Arms .............................................................179
Rear A-Arms..............................................................182
Rear Knuckles...........................................................184
Wheels and Tires ......................................................185
Troubleshooting.........................................................186

2
General Information/
Foreword
This Service Manual contains service, maintenance, and
troubleshooting information for the 2021 800SX model.
The complete manual is designed to aid service personnel
in service-oriented applications.
This manual is divided into sections. Each section covers
a specific vehicle component or system and, in addition
to the standard service procedures, includes disassem-
bling, inspecting, and assembling instructions. When
using this manual as a guide, the technician should use
discretion as to how much disassembly is needed to cor-
rect any given condition.
This service manual is designed primarily for use by a
basic level service technician. The procedures found in
this manual are of varying difficulty, and certain service
procedures in this manual require one or more special
tools to be completed. The technician should use sound
judgment when determining which procedures can be
completed based on their skill level and access to appro-
priate special tools.
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
When replacement of parts is necessary, use only genuine
parts. They are precision-made to ensure high quality and
correct fit. Refer to the appropriate Illustrated Parts Man-
ual for the correct part number, quantity, and description.
All publications and decals display the words Warning,
Caution, Note, and At This Point to emphasize important
information. The symbol !WARNINGidentifies
personal safety-related information. Be sure to follow the
directive because it deals with the possibility of serious
personal injury or even death. A CAUTION identifies
unsafe practices which may result in vehicle-related dam-
age. Follow the directive because it deals with the possi-
bility of damaging part or parts of the vehicle. The
symbol NOTE: identifies supplementary information
worthy of particular attention. The symbol AT
THIS POINT directs the technician to certain and
specific procedures to promote efficiency and to improve
clarity.
At the time of publication, all information, photographs,
and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes
only and are not designed to depict actual conditions.
Because products are constantly refined and improved,
no retroactive obligation is incurred.
All materials and specifications are subject to change
without notice.
Specifications
 NOTE: Specifications subject to change without notice.
MISCELLANEOUS
Tire Size (Front) 26 x 9 R14
26 x 10 R14
27 x 9 R14
Tire Size (Rear) 26 x 10 R14
26 x 11 R14
27 x 11 R14
Front Tire Inflation Pressure (cold) 83 kPa (12 psi)
Rear Tire Inflation Pressure (cold) 96.5 kPa (14 psi)
Fuel Tank Capacity 37.85 L (10 U.S. gal.)
Coolant Capacity 5.67 L (6 U.S. qt)
Front Differential Capacity 198 ml (6.7 fl oz)
Transaxle Capacity 1.21 L (41 fl oz)
Engine Oil Capacity (approx) 2.37 L (2.5 U.S. qt)
Gas (recommended) Regular unleaded 87 octane
(R+M)/2, ethanol content not
to exceed 10%
Engine Oil (recommended) 0W-40 Synthetic
Front Differential Lubricant SAE-Approved 80W-90
Hypoid
Transaxle Lubricant Transaxle Fluid with EP
Drive Belt Width (min) 30 mm (1.2 in.)
Brake Fluid DOT 4
Taillight/Brake Light 12.8V-27W/14V-8W
Headlight 12V/60/55W
Engine Idle RPM 950 ± 50
Engine Max RPM 6300
ELECTRICAL SYSTEM
Alternator Output 75 amps (max)
VALVES AND GUIDES
Valve/Tappet Clearance (intake)
(cold engine) (exhaust)
0.13-0.23 mm
0.20-0.30 mm
Valve Guide/Stem Clearance (intake)
(exhaust)
0.07 mm (limit)
0.08 mm (limit)
Valve Guide Inside Diameter 5.0 mm (standard)
Valve Spring Free Length 37 mm (benchmark)
Valve Spring Distortion 1.2 mm (limit)
CYLINDER, PISTON, AND RINGS
Cylinder Bore Out-Of-Round 0.03 mm (limit)
Piston to Cylinder Clearance 0.10 mm (limit)
Piston Ring Groove Clearance 0.12 mm (limit primary)
0.11 mm (limit secondary)
Piston Ring End Gap 0.65 mm (limit primary)
0.65 mm (limit secondary)
1.00 mm (limit oil ring)
CRANKSHAFT
Crankshaft Main Bearing Journal 0.10 mm (limit)
Crankshaft Connecting Rod Journal
(min)
0 07 mm (limit)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (intake/exhaust) (min) 22.9 mm
Cylinder Head Distortion (max) 0.10 mm

3
Torque Specifications
NOTE: Torque specifications have the following tol-
erances:
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
Part Part Bolted to Torque
ft-lb N-m
EXHAUST COMPONENTS
Exhaust Pipe Flange Cylinder Head 45 61.2
Exhaust Pipe Muffler 16 21.8
Oxygen Sensor Exhaust Pipe 20 27.2
INTAKE COMPONENTS
Air Cleaner Mount Frame 16 21.8
Intake Hose 2” Elbow Manifold & Intake Duct 11 in-
lb
1.25
Intake Hose 2” Elbow Intake Duct & Air Cleaner
Assembly
11 in-
lb
1.25
Intake Hose Inlet Air Cleaner Assembly 11 in-
lb
1.25
Clamp Frame 17 in-
lb
1.92
COOLING COMPONENTS
Radiator Bracket Frame Stamping 20 27.2
FUEL SYSTEM COMPONENTS
Fuel Pump Fuel Tank 70 95.2
BRAKE COMPONENTS
Master Cylinder Frame 16 21.8
Master Cylinder Remove Tank Frame 4 5.4
Rear Brake Hose Master Cylinder 20 27.2
Rear Brake Hoses Hydraulic Caliper 20 27.2
Front Brake Hose Master Cylinder 20 27.2
Front Brake Hoses Hydraulic Caliper 20 27.2
Rear Brake Hose Frame 6 8.2
Front Brake Hose Frame 6 8.2
Brake Pedal Frame 16 21.7
Knuckle Front Brake Caliper 45 61.2
Knuckle Rear Brake Caliper 45 61.2
ACCELERATOR COMPONENTS
Accelerator Pedal Splash Panel 8 10.9
SHIFTER COMPONENTS
Tilt Steering Sub-Assembly Frame 16 21.8
Steering Column Support
Bracket
Steering Column 24 in-
lb
2.72
Shifter Cable Eyelet Shifter Column Casting 6 8.2
Shift Cable Threads Tilt Steering Sub-Assembly 20 27.2
Shift Cable Threads Shift Cable Bracket
Transaxle
20 27.2
Shift Lever Shifter Knob 20 27.2
Shift Cable Bracket Transaxle 8 10.9
ELECTRICAL COMPONENTS
Tilt Sensor Frame 5 6.8
Starter Solenoid Frame 10 13.6
Ground Wire Engine 16 21.8
ECM Behind Seat Storage Box 12 in-
lb
1.36
Starter Engine Backplate 14.8 20
Alternator Pivot Engine Block 33.2 45
Alternator Adjuster Alternator Bracket 14.8 20
PDM Bracket Frame 10 13.6
STEERING COMPONENTS
Rack & Pinion Housing Bracket, Rack Mount 16 21.8
Part Part Bolted to Torque
ft-lb N-m
STEERING COMPONENTS (cont.)
Bracket Rack Mount Frame (with weld nut) 45 61.2
Bracket Rack Mount Frame (with nut) 16 21.8
Intermediate Shaft Rack & Pinion 45 61.2
Steering Shaft Steering Wheel 25 34
Tilt Steering Subassembly Frame 16 21.8
Bracket Steering Column
Support
Steering Column 24 in-
lb
2.72
Tilt Steering Shock Bracket Steering Column
Support
68.2
Tilt Steering Shock Frame 6 8.2
EPS Mount Brackets Frame 16 21.8
EPS Mount Brackets EPS Unit 16 21.8
Intermediate Shaft EPS Unit 24 32.6
CHASSIS ASSEMBLY
Skid Plates Frame 6 8.2
Bumper Frame 16 21.8
Front Engine Bracket —
Driver Side
Frame 45 61.2
Front Engine Bracket —
Passenger Side
Frame 45 61.2
Front Engine Bracket —
Driver & Passenger Side
Front Engine Mount
Assembly
16 21.8
Seat Structure Frame 6 8.2
Bumper Bracket Frame 20 27.2
Rubber Mount Engine Bracket 45 61.2
Tow Hook Frame 20 27.2
Cargo Box Hinge Point Frame 30 40.8
Cargo Box Shock Frame/Cargo Box 10 13.6
SEAT ASSEMBLY
Driver Seat Tube Driver Seat Base/Backrest 2 2.7
Seat Slider Seat Tube 8 10.9
Seat Slider Seat Structure 2 2.7
Seat Bracket Seat Tube 8 10.9
Lock Handle Seat Bracket 8 10.9
Seat Belt Retractor/Anchor Frame 60 81.6
Seat Belt D-loop Rear ROPS 35 47.6
ROPS ASSEMBLY
Canopy Front Hoop Frame 45 61.2
Canopy Front Hoop Canopy Rear Hoop 45 61.2
Canopy Rear Hoop Frame 45 61.2
Shoulder Restraint Upper Frame 20 27.2
Shoulder Restraint Lower Frame 20 27.2
Flag Mount Bracket Canopy Rear Hoop 6 8.2
SUSPENSION COMPONENTS (Front)
Front Shock Frame/Upper A-Arm 45 61.2
Upper A-Arms Frame 45 61.2
Lower A-Arms Frame 45 61.2
Ball Joint Knuckle 45 61.2
Knuckle** Tie Rod End 32 43.5
Knuckle Assembly/Front Hub Front Axle 250 339
Sway Bar Mount Frame 20 27.2
Sway Bar Link Sway Bar (1-2 threads
exposed)
Sway Bar Link A-arm (5-6 threads
exposed)
SUSPENSION COMPONENTS (Rear)
Upper A-Arms Frame 45 61.2
Lower A-Arms Frame 45 61.2
Lower A-Arm Knuckle Assembly 45 61.2
Upper A-Arm Knuckle Assembly 45 61.2
Rear Shock Upper A-Arm 45 61.2
Rear Shock Frame 45 61.2
Knuckle Assembly/Rear Hub Rear Axle 250 339

4
* w/Blue Loctite #243 ** w/Red Loctite #271
Torque Conversions
(ft-lb/N-m)
Gasoline — Oil — Lubricant
FILLING GAS TANK
Since gasoline expands as its temperature rises, the tank must
be filled to its specified capacity only. Expansion room must
be maintained in the tank particularly if the tank is filled with
cold gas and then moved to a warm area.
Tighten the gas tank cap securely after filling the tank.
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates are added to
the gasoline. Oxygenated gasolines containing up to 10%
ethanol or 5% methanol are acceptable gasolines.
Part Part Bolted to Torque
ft-lb N-m
DRIVE TRAIN COMPONENTS
Top Differential Mount Frame 16 21.8
Frame Lower Differential Mount 16 21.8
Differential Top Differential Mount 45 61.2
Differential Bottom Differential Mount 45 61.2
Drain Plug Front Differential 45 in-
lb
5.09
Oil Inspection Plug Front Differential 45 in-
lb
5.09
Fill Plug Front Differential 16 21.8
Rear Transaxle Mount Bracket Transaxle 45 61.2
Engine Backplate/Transaxle* Engine/Transaxle Bracket 75 102
Transaxle Mount Bracket* Engine 55 74.8
Rear Transaxle Mount Bracket Rear Rubber Mounts 45 61.2
Rear Rubber Mounts Frame 45 61.2
Driven Clutch Transaxle 60 81.6
Drive Clutch Engine 60 81.6
Speed Sensor Transaxle 10 13.6
Drain Plug Transaxle 16 21.8
Fill Plug Transaxle 16 21.8
Wheel Hub (20 ft-lb increments) 100 136
CVT Inlet/Exhaust Tubes Hose Clamp 15 in-
lb
1.70
CVT Exhaust Tube CVT Exhaust Support
Bracket
17 in-
lb
1.92
Inner Clutch Cover Transaxle 8 10.9
Driven Cam Driven Clutch 47 in-
lb
5.3
Drive Clutch Cover Drive Clutch 110
in-lb
12.4
Drive Clutch Cam Arms Drive Clutch 50 in-
lb
5.6
Flywheel Engine Crankshaft 51.7 70
PTO Stub Shaft Flywheel 36.9 50
ENGINE ASSEMBLY
Drain Plug Oil Pan 36.9 50
Front Engine Mount Engine 55 74.8
Front Engine Mount Backplate 20 27.2
Crankshaft Sensor Bracket Backplate 8 10.9
Crankshaft Sensor Crankshaft Sensor Bracket 8 10.9
Connecting Rod Cap Connecting Rod (4 Steps) 29.5 40
Main Bearing Cap Engine Block (6 Steps) 51.7 70
Camshaft Caps Cylinder Head 6.7 9
Cylinder Head Cylinder (5 steps) 51.7 70
Oil Pump Engine Block 14.8 20
Serpentine/Timing Belt Pulley Crankshaft 73.8 100
Camshaft Timing Belt Pulley Camshaft 73.8 100
Timing Belt Idler Nut Engine Block 18.5 25
Timing Belt Cover Engine 4.5 6
Oil Pan Crankcase 7.4 10
Crankshaft Seal/Flange Engine Block 14.8 20
Thermostat Housing Cylinder Head 14.8 20
Water Pump Engine Block 14.8 20
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
! WARNING
Always fill the gas tank in a well-ventilated area. Never add
gas to the tank near any open flames or with the engine run-
ning. DO NOT SMOKE while filling the tank.
! WARNING
Do not overflow gasoline when filling the tank. A fire
hazard could materialize. Always allow the engine to
cool before filling the gas tank.
! WARNING
Do not over-fill the gas tank.

5
When using ethanol-blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
RECOMMENDED ENGINE OIL
The recommended oil to use is ACX All Weather syn-
thetic engine oil, which has been specifically formulated
for use in this engine. Although All Weather synthetic
engine oil is the only oil recommended for use in this
engine, use of any API-certified 0W-40 oil is acceptable.
OILCHARTJ
RECOMMENDED FRONT
DIFFERENTIAL LUBRICANT
The recommended lubricant is SAE-approved 80W-90
hypoid. This lubricant meets all of the lubrication
requirements of the vehicle’s front differential.
RECOMMENDED TRANSAXLE
LUBRICANT
The recommended lubricant is transaxle fluid with EP.
This lubricant meets all of the lubrication requirements of
this vehicle’s transaxle.
Preparation for Storage
The manufacturer recommends the following procedure
to prepare the vehicle for storage. An authorized dealer
should perform this service; however, the owner/operator
may perform this service if desired.
1. Clean the vehicle thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire vehi-
cle. Allow the vehicle to dry thoroughly. DO NOT
get water into any part of the engine or air intake.
2. Either drain the gas tank or add a fuel stabilizer to the
gas in the gas tank.
3. Clean the interior of the air filter housing.
4. Plug the hole in the exhaust system with steel wool.
5. Apply light oil to the upper steering shaft bushing
and plungers of the shock absorbers.
6. Tighten all nuts, bolts, cap screws, and screws. Make
sure rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, cap screws, and bolts are tightened to
specifications.
7. Fill the cooling system to the recommended level
with properly mixed coolant.
8. Disconnect the battery cables (negative cable first);
then remove the battery, clean the battery posts and
cables, and store in a clean, dry area.
NOTE: For storage, use a battery maintainer or
make sure the battery is fully charged (see Battery
section in this manual).
9. Store the vehicle indoors in a level position.
CAUTION
Do not use white gas. Only approved gasoline additives
should be used.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. Also, not
recommended are racing, vegetable, non-detergent, and
castor-based oils.
CAUTION
Any lubricant used in place of the recommended lubri-
cant could cause serious front differential/rear drive
damage.
CAUTION
Prior to storing this vehicle, it must be properly ser-
viced to prevent rusting and component deterioration.
CAUTION
Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the vehicle
causing rusting.

6
Preparation after Storage
Taking this vehicle out of storage and correctly preparing
it will ensure many hours of trouble-free riding. The
manufacturer recommends the following procedure:
1. Clean the vehicle thoroughly.
2. Remove the steel wool from the exhaust system.
Clean the spark arrestor.
3. Check all control wires and cables for signs of wear
or fraying. Replace if necessary.
4. Change the engine oil and filter. Change the tran-
saxle fluid. Change the front differential fluid.
5. Check the coolant level and add properly mixed
coolant as necessary.
6. Charge the battery; then install. Connect the battery
cables making sure to connect the positive cable
first.
7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brake light,
and headlight aim; adjust or replace if necessary.
8. Check the tire pressure. Inflate to recommended
pressure as necessary.
9. Tighten all nuts, bolts, cap screws, and screws mak-
ing sure all calibrated nuts, cap screws, and bolts are
tightened to specifications.
10. Make sure the steering moves freely and does not
bind.
11. Check the air filter and the air filter housing. Clean
or replace as necessary.
12. Check the spark plugs. Clean or replace as necessary.
CAUTION
Before installing the battery, make sure the ignition
switch is in the OFF position.

7
Periodic Maintenance/
Tune-Up
Tighten all nuts, bolts, and cap screws. Care must be
taken that all calibrated nuts, bolts, and cap screws are
tightened to specifications.
It is advisable to lubricate certain components periodi-
cally to ensure free movement. Apply light oil to the
components using the following list as reference:
A. Accelerator Pedal Pivot
B. Brake Pedal Pivot
C. Shift Cable
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
NOTE: When indicated for use, each special tool
will be identified by its specific name, as shown in the
chart below, and capitalized.
NOTE: Special tools are available from the Service
Department.
CVT Air Inlet
This vehicle is equipped with an air inlet to collect air for
the Continuously Variable Transmission (CVT).
NOTE: When servicing clutches or belt, it is recom-
mended to inspect and clean the CVT air inlet.
1. Remove the left-side access panel; loosen the clamp
that holds the snorkel portion to the air inlet.
MOD205
2. Disconnect snorkel portion from air inlet; clean and
inspect.
3. Install the snorkel to the air inlet and tighten the
clamp securely. Reinstall the left-side access panel.
Engine Air Filter
Primary Air Filter/Safety Filter/Clean-
out Valve
The engine air filter inside the air filter housing must be
kept clean to provide good engine power and fuel mile-
age. If the vehicle is used under normal conditions, ser-
vice the filter at the intervals specified. If operated in
dusty, wet, or muddy conditions, inspect and service the
filter more frequently. Use the following procedure to
clear the clean-out valve, remove the primary filter and
safety filter, and inspect and/or clean them.
NOTE: To access the air filter housing, the right-
side access panel must be removed and the cargo box
raised if desired.
REMOVING AND INSPECTING
1. Remove dirt and debris from around the air filter
housing cover; then squeeze the clean-out valve to
clear it of any accumulated dirt or dust.
2. Check the clean-out valve for cracks or damage.
Replace as needed.
MOD085
3. Pull out on the orange air filter housing cover lock;
then turn the air filter housing cover counterclock-
wise to access the filter.
Description p/n
Drive and Driven Clutch Holder Tool 0444-317
Hub Retaining Wrench 0444-270
CAUTION
Failure to inspect the air filter frequently if the vehicle is
used in dusty, wet, or muddy conditions can damage
the engine.

8
MOD084A
MOD084B
4. Loosen the clamp indicated and disconnect the snor-
kel from the housing; then clean and inspect the
inside of the snorkel; then remove the primary air fil-
ter element; then wipe the inside of the housing to
remove dirt and debris.
MOD597
MOD598
MOD086
MOD087
5. Inspect the primary air filter element for damage or
dirt. If damaged the filter must be replaced.
6. A dust trail anywhere inside of the air filter housing,
inlet tube or on the safety filter is a telltale sign of a
leak. Leaks should be inspected by an authorized
dealer.
MOD088
CAUTION
Do not attempt to clean the primary filter or filter dam-
age may occur.
CAUTION
When replacing the primary filter, always inspect the
new filter for damage. Never install a damaged filter. Do
not wipe the new filter as it is lubricated for sealing pur-
poses.

9
MOD089
7. Remove and inspect the safety filter.
MOD090
INSTALLING
1. Install safety filter; then install the primary filter.
NOTE: The flower shape of the primary filter ele-
ment must line up with the same-shaped void in the
air filter housing for the air filter housing cover to fit
properly.
MOD091A
MOD092
2. Install the air filter housing cover with the clean-out
valve at the 5 o’clock position; then turn the air filter
housing cover clockwise until it seats.
NOTE: The clean-out valve should be near the
6 o’clock position when the cover is seated.
3. Lock the air filter housing cover.
MOD084C
MOD084A
4. Connect the snorkel to the housing; then tighten the
clamp securely.

10
MOD597
5. Install the right access panel and secure with two
1/4-turn fasteners.
Valve Clearance
Checking Valve Clearance
NOTE: The engine does not need to be removed
from the vehicle for this procedure.
1. Disconnect the negative battery cable; then remove
the valve cover (see REMOVE AND INSTALL
VA LV E C O V E R ) .
NOTE: There are two intake and two exhaust
valves per cylinder. The intake camshaft and valves
are next to the intake manifold and the exhaust cam-
shaft and valves are next to the exhaust manifold.
2. Remove the spark plugs, making sure no dirt or for-
eign material enters the cylinders.
MF034B
3. Using a suitable bar, turn the crankshaft in the direc-
tion of rotation until the highest section of the cam-
shaft lobes (A) of the valves to be checked are
pointing directly away from the valve bucket (B).
MF039A
MF078A
4. Using a suitable feeler gauge, check clearance
between the camshaft and the valve bucket recording
the value when a slight drag is felt when inserting
and retracting the gauge blade.
MF037
5. Repeat and record clearance values for all remaining
valves
NOTE: Intake valve clearance specification is 0.18 ±
0.05 mm (0.007 ± 0.002 in.). Exhaust valve clearance
specification is 0.25 ± 0.05 mm (0.010 ± 0.002 in.).
6. Install the valve cover (see REMOVE AND
INSTALL VALVE COVER); then connect the bat-
tery cables.
CAUTION
A torn air filter can cause damage to the engine. Dirt
and dust may get inside the engine if the element is
torn. Carefully examine the element for tears before and
after cleaning it. Replace the element with a new one if it
is torn.

11
Spark Plug
A light brown insulator indicates that the plug and fuel/
air ratio are correct. A white or dark insulator indicates
that the engine may need to be serviced. To maintain a
hot, strong spark, keep the plug free of carbon.
ATV-0051
Adjust the gap to 1.0 mm (± 0.1 mm).
ATV0052
Tighten spark plug to 14.75 ft-lb (20 N-m).
Muffler/Spark Arrester
The muffler has a spark arrester which must be periodi-
cally cleaned. At the intervals shown in the Maintenance
Schedule, clean the spark arrester using the following
procedure.
1. Remove the cap screw securing the spark arrester
assembly to the muffler.
MOD095A
2. Using a suitable brush, clean the carbon deposits
from the screen taking care not to damage the screen.
NOTE: If the screen is damaged in any way, it must
be replaced.
3. Install the spark arrester assembly and secure with
the cap screw. Tighten to 60 in.-lb (6.8 N-m).
Engine Oil — Filter
Change the engine oil and oil filter at the scheduled inter-
vals. The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
1. Park the vehicle on level ground.
2. Remove the maintenance cover to access the oil fil-
ter.
MOD105
3. Tilt the cargo box to the dump position; then loosen
the oil fill cap. Be careful not to allow contaminants
to enter the opening.
CAUTION
Before removing the spark plug, be sure to clean the
area around the spark plug. Dirt could enter engine
when removing or installing the spark plug.
! WARNING
Wait until the muffler cools to avoid burns.

12
MOD064
4. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan.
MOD020A
5. Using the oil filter wrench and a ratchet handle (or a
socket or box-end wrench), remove the old oil filter
and dispose of properly. Capture oil in a suitable pan
or absorbent material. Do not re-use oil filter.
MOD106
NOTE: Clean up any excess oil after removing the
filter.
6. Apply oil to the new filter O-ring and check to make
sure it is positioned correctly; then install the new oil
filter. Tighten securely.
7. Install the engine drain plug and tighten to 36.9 ft-lb
(50 N-m). Pour the recommended oil into the filler
hole. Install oil fill cap.
8. Start the engine (while the vehicle is outside on level
ground) and allow it to idle for a few minutes.
9. Turn the engine off and wait
approximately one min-
ute . Recheck the oil level.
10. Inspect the area around the drain plug and oil filter
for leaks.
11. Install the maintenance cover.
12. Check to make sure the oil fill cap is secure and the
oil level stick is installed correctly; then lower the
cargo box to its locked down position.
Front Differential Lubricant
— Transaxle Fluid
INSPECTING/CHANGING
Inspect and change the lubricant/fluid in each according
to the Maintenance Schedule. Use the appropriate lubri-
cant and the following procedure:
1. Place the vehicle on level ground; then remove the
fill plugs on the front differential (A) and transaxle
(C).
MOD073A
MOD058A
2. Drain the lubricant/fluid into a drain pan by remov-
ing the drain plugs from the right-side front differen-
tial (E) and transaxle (D).

13
MOD126A
MOD058A
3. After the lubricant/fluid has been drained, install the
drain plugs and tighten to 45 in.-lb (5.1 N-m) (front
differential) and 16 ft-lb (21.8 N-m) (transaxle).
4. Pour recommended quantity and type of lubricant/
fluid into each fill hole (see photos MOD073A and
MOD058A above) as follows:
Front differential fill plug (A) — add lubricant until it is
level with the lubricant inspection plug (B).
Transaxle fill and fluid inspection plug (C) — add fluid
until it is level with the bottom of (C).
5. Install the fill plugs and tighten to 16 ft-lb (21.8 N-m)
and install the front differential lubricant inspec-
tion plug to 45 in-lb (5.1 N-m).
NOTE: If the lubricant/fluid is contaminated with
water, inspect the drain plug, fill plug, and/or seals.
Driveshaft/Coupling
The following drive system components should be
inspected periodically to ensure proper operation:
A. Spline lateral movement (free-play).
B. Coupling cracked, damaged, or worn.
Headlight — Taillight/Brake
Light
Light Bulb Replacement
NOTE: The bulb portion of the headlight is fragile.
HANDLE WITH CARE. When replacing the head-
light bulb, do not touch the glass portion of the bulb.
If the glass is touched, it must be cleaned with a dry
cloth before installing. Skin oil residue on the bulb
will shorten the life of the bulb.
To replace the headlight bulb, use the following proce-
dure:
1. Disconnect the wiring harness; then remove the rub-
ber boot from the light assembly.
MOD046
MOD096
2. Remove the old H4 bulb by unlocking the spring;
then insert the new bulb into headlight assembly and
lock the spring to secure the bulb.
CAUTION
Inspect the lubricant/fluid for any signs of metal filings
or water. If found, take the vehicle to an authorized
dealer for servicing.
CAUTION
Use only specified bulbs indicated in the Specifications
chart as replacement bulbs.
CAUTION
When replacing the headlight bulb, do not touch the
glass portion of the bulb. Grasp the new bulb with clean
rubber gloves.

14
MOD097A
3. Install the rubber boot making sure it is sealed
around the bulb and connect the wire harness.
MOD098A
4. Adjust the headlight (see Checking/Adjusting Head-
light Aim in this sub-section.
Taillight/Brake Light Assembly
If one or more individual LED bulbs are not working, the
taillight/brake light assembly must be replaced.
MOD096
To replace the taillight/brake light assembly, use the fol-
lowing procedure:
1. Remove the four screws from the inner cargo box
side panel, two rear tie-down screws and one tailgate
latch bail screw; then remove the six screws from the
underside of the cargo box and remove the outer
cargo box side panel.
MOD114A
MOD115A
2. Remove screw (A); then flex the cargo box fender
away from the cargo box to access and remove screw
(B).
NOTE: A long extension with a T25 socket or long
T25 screwdriver will be needed to access screw (B).
MOD117A
MOD113

15
3. Remove the taillight/brake light assembly and dis-
connect it from the harness by pushing on the con-
nector lock.
MOD110
MOD112A
4. Install the new assembly, making sure to connect the
harness.
MOD112
5. Install screw (A) first; then flex the cargo box fender
away from the cargo box to access and install screw
(B).
MOD117A
MOD113
6. Position the outer cargo box side panel behind the
two tabs on the cargo box fender; then fit all tabs into
their adjoining slots in the side panel.
MOD116A
7. With a suitable pry bar, lift up on the inner cargo box
floor near the rear corner.
MOD110A

16
8. Start at the rear of the cargo box and tuck the outer
side panel under the cargo box floor and work it into
place from back to front.
MOD111
9. Once the outer side panel is in place, install the
screws securing the cargo box fender and outer side
panel.
MOD114A
MOD115A
Checking/Adjusting Headlight Aim
The headlights can be adjusted vertically. The geometric
center of the HIGH beam light zone is to be used for aim-
ing.
1. Position the vehicle on a level floor so the headlights
are approximately 6.1 m (20 ft) from an aiming sur-
face (wall or similar aiming surface).
MOD38
NOTE: There should be an average operating load
on the vehicle when adjusting the headlight aim.
2. Measure the distance from the floor to the midpoint
of each headlight.
3. Using the measurements obtained in step 2, make
horizontal marks on the aiming surface.
4. Make vertical marks which intersect the horizontal
marks on the aiming surface directly in front of the
headlights.
5. Switch on the lights. Make sure the HIGH beam is
on. DO NOT USE LOW BEAM.
6. Observe each headlight beam aim. Proper aim is
when the most intense beam is centered on the verti-
cal mark 5 cm (2 in.) below the horizontal mark on
the aiming surface.
7. Turn the headlight adjustment cap screw clockwise
to adjust the headlight aim down or counterclock-
wise to adjust the headlight aim up.
MOD046A
Shift Cable
CHECKING SHIFT CABLE
Turn the ignition switch on; then shift the transmission
into park. The letter P should illuminate on the LCD
gauge and the park icon (P) should illuminate. The vehi-
cle should not be able to move.

17
MOD207
Move the shift lever all the way back. The letter L should
illuminate on the LCD gauge.
MOD208
If either park or low range cannot be reached, the shift
cable must be adjusted.
ADJUSTING SHIFT CABLE
1. Secure the vehicle on a support stand to elevate the
wheels; then place the transmission in neutral; then
rotate the rear wheels by hand at least two revolu-
tions.
2. Tilt the cargo box up; then remove the passenger-
side rear inner fender. With the gear selector in neu-
tral, measure the distance on each side of the upper
tilt steering wheel adjuster bracket and the shifter
housing.
MOD520
NOTE: If the distance on each side of the upper tilt
steering wheel adjuster bracket and the shifter hous-
ing is the same and the vehicle does not properly
engage Park or Low, shift cable replacement may be
required.
3. Loosen nuts (A) and (B) and adjust the cable housing
until the measurements on each side of the upper tilt
steering wheel adjuster bracket are the same.
MOD297
4. Tighten the nuts (A) and (B) to 20 ft-lb (27.2 N-m).
5. Check each gear shift position for proper gear selection
and make sure the proper icon illuminates on the LCD.
Hydraulic Brake System
NOTE: This ROV/UTV is equipped with hydraulic
brakes at all four wheels.
CHECKING/BLEEDING
The hydraulic brake system has been filled and bled at
the factory.
1. With the master cylinder in a level position, check
the fluid level in the reservoir. If the level in the res-
ervoir is not above the MIN, add DOT 4 brake fluid.
MOD163
2. Depress the brake pedal several times to check for a
firm brake. If the brake is not firm, the system must
be bled. To bleed the brake system, use the following
procedure:
A. Remove the cover and fill the reservoir with
DOT 4 brake fluid; then install and secure the
cover.
! WARNING
Make sure the vehicle is solidly supported on the sup-
port stand to avoid injury.

18
B. Slowly depress the brake pedal several times.
C. Install one end of a clear hose onto the RIGHT
REAR bleeder screw and direct the other end
into a container; then while holding slight pres-
sure on the brake pedal, open the bleeder screw
and watch for air bubbles. Close the bleeder
screw before releasing the brake pedal. Repeat
this procedure until no air bubbles are present.
MOD299
MOD300
NOTE: During the bleeding procedure, watch the
reservoir very closely to make sure there is always a
sufficient amount of brake fluid. When the level falls
below MIN, refill the reservoir before the bleeding
procedure is continued. Failure to maintain a suffi-
cient amount of fluid in the reservoir will result in air
in the system.
D. At this point, perform steps B and C on the
REAR LEFT bleeder screw; then move to the
FRONT RIGHT bleeder screw and follow the
same procedure. Finally, complete the procedure
on the FRONT LEFT bleeder screw.
MOD161
E. Repeat steps B and C until the brake pedal is
firm.
3. Carefully check the entire hydraulic brake system to
ensure all hose connections are tight, the bleed
screws are tight, the protective caps are installed, and
no leakage is present.
INSPECTING HOSES
Carefully inspect the hydraulic brake hoses for cracks or
other damage. If found, the brake hoses must be replaced.
CHECKING/REPLACING PADS
The clearance between the brake pads and brake discs is
adjusted automatically as the brake pads wear. The only
maintenance that is required is replacement of the brake
pads when they show excessive wear. Check the thick-
ness of each of the brake pads as follows.
1. Remove the wheel corresponding to the brake being
checked.
2. Measure the thickness of each brake pad.
MOD081A
3. If thickness of either brake pad friction material is
less than 0.5 mm (0.019 in.), the brake pads must be
replaced.
NOTE: The brake pads should be replaced as a set.
4. To replace the brake pads, use the following proce-
dure:
A. Remove the Torx head plug from the caliper;
then remove the cap screws securing the caliper
holder to the knuckle.
MOD512
FRONT
CAUTION
This hydraulic brake system is designed to use DOT 4
brake fluid only. If brake fluid must be added, care must
be taken as brake fluid is very corrosive to painted sur-
faces.